Grip enhancing structure having vacuum adhesion micro, miniature_suction cups and method and apparatus for making same

ABSTRACT

A vacuum adhesion-gripping surface is provided by an array of miniature suction cups. The surface is provided on a glove or other object for which an improved grip is desired. The miniature suction cups are of very small sizes and high densities. The vacuum adhesion micro suction cups are formed with a tooling structure having a pair of plates. A first plate includes a plurality of holes and a second plate includes a plurality of pins. When the plates are placed together, small cavities are created between the holes and pins for forming an array of vacuum adhesion micro suction cups using a molding or similar process. Alternatively a glove, such as a medical glove, utilizing the micro suction cup gripping design can be made using a dipping process.

CROSS REFERENCES

This application is a continuation-in-part of U.S. patent application Ser. No. 11/271,152, filed Nov. 9, 2005. It further claims priority to U.S. Provisional Application Nos. 60/626,356 and 60,627,861, filed Nov. 9, 2004 and Nov. 15, 2004, respectively.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a surface manufactured as an integrated part of objects for improving gripping. More particularly, it relates to a material having micro miniature suction cups on a glove or other object for improved gripping performance.

2. Discussion of Related Art

Various types of work, medical, military and athletic gloves are used to increase the gripping strength and control of the user. Some such gloves have friction material at least at locations where the user's hand contacts the object. However, the gripping capacity of the friction material can significantly decrease under certain conditions, such as water or other foreign matter on the glove or the object. Furthermore, friction material provides little increase in gripping capacity for objects.

Several structures on the surface of a glove have been proposed to provide improved gripping strength and control. U.S. Pat. No. 6,081,928 discloses a glove with enhanced grip strength through the use of indentations that form a suction area. Alternatively, it discloses a glove with suction cups formed on the surface. Similarly, U.S. Pat. No. 6,427,248 discloses a grip-enhancing glove with suction cups of 1/16 “and larger. These structures work best on smooth surfaces. They are unable to provide an enhanced grip for uneven or irregular surfaces.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a glove has an enhanced gripping surface. The enhanced gripping surface is achieved through the use of extremely small micro sized suction cups. The suction cups have a diameter of less than 1/16 of an inch. According to one aspect of the invention, the suction cup diameter is approximately 0.031 inch. According to another aspect of the invention, the micro suction cups have a density greater than 300 per square inch. According to another aspect of the invention, the micro suction cups have a density of approximately 600 per square inch. According to another aspect of the invention the micro suction cups have a density of 1000 per square inch. According to another aspect of the invention, the micro suction cup density is determined by the amount of grip required. According to another aspect of the invention, the micro suction cups of the vacuum enhanced gripping surface have a conical shape.

According to another aspect of the invention, the enhanced vacuum gripping micro suction cups are manufactured as an integral part of a surface. According to another aspect of the invention, the array of vacuum adhesion micro suction cups is imbedded into a surface. According to another aspect of the invention, the array of vacuum adhesion micro suction cups is formed as part of a surface.

According to another aspect of the invention, specialized tooling and manufacturing process is used to form an array of vacuum grip enhancing micro suction cups. The tooling includes a first plate having a plurality of holes corresponding to the plurality of suction cups. Each hole includes a cylindrical end and a conical shoulder. The tooling includes a second plate having a plurality of small diameter pins. Each of the pins is positioned to fit within a hole in the first plate. Each pin has a conical top surface. When the two plates are engaged, a space remains between the top surface of each pin and the conical shoulder of the corresponding hole. According to another aspect of the invention, a process for creating the tooling allows the formation of a dense array of suction cups. The process utilizes a casting plate for forming the pins. A plurality of holes is drilled into the casting plate. The shape of the holes corresponds to the shape of the pins. The second plate with the pins is formed through casting into the drilled holes. A first plate is machined with holes matching the cast pins of the second plate and suction cup shape.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a plurality of micro sized suction cups forming a grip-enhanced surface according to an embodiment of the present invention.

FIG. 2 is a cross sectional view of one of the suction cups of FIG. 1.

FIG. 3 is a plan view of the first tooling plate according to a first embodiment of the invention.

FIG. 4 is a cross sectional view of the second tooling plate of FIG. 3.

FIG. 5 is a cross sectional view of a void created by the assembly of the first tooling plate and second tooling plate according to the first embodiment of the present invention.

FIG. 6 is a plan view of the first tooling plate according to an embodiment of the invention.

FIG. 7 is a cross sectional view of a void created by the assembly of the first tooling plate and second tooling plate according to a second embodiment of the present invention.

FIG. 8 is a cross sectional view of a void created by the assembly of the first tooling plate and second tooling plate according to a third embodiment of the present invention.

FIG. 9 is a cross sectional view of a void created by the assembly of the first tooling plate and second tooling plate according to a fourth embodiment of the present invention.

FIG. 10 is a cross sectional view of a void created by the assembly of the first tooling plate and second tooling plate according to a fifth embodiment of the present invention.

FIG. 11 is a cross sectional view of a tooling system for formation of a second tooling plate according to an embodiment of the present invention.

FIG. 12 is a view of a glove with strategically placed vacuum adhesion micro suction cups according to an embodiment of the invention.

FIG. 13 is a view of a glove with vacuum adhesion micro suction cups according to an another embodiment of the invention.

DETAILED DESCRIPTION

The present invention relates to a grip enhancing vacuum adhesion structure. The structure can be added to a glove, shoe or other object to provide an improved vacuum adhesion grip. The material includes a plurality of miniaturized vacuum adhesion micro sized suction cups formed in an array. The processes of the present invention allow suction cups to be formed having diameters on the order of 0.055 inches or less. Of course, any other smaller diameter can be used. Such suction cups are smaller than prior art suction cups. Suction cups of this size are not clearly visible to the naked eye as suction cups. The grip-enhanced surface appears as a texture. However, the array of vacuum adhesion micro sized suction cups can provide significant holding power when touching different surfaces. The vacuum grip due to its size can adhere to more surfaces than standard suctions cups that exist in other designs.

A first embodiment of the present invention is illustrated in the perspective view of FIG. 1. The first embodiment 10 includes a plurality of miniaturized vacuum adhesion micro sized suction cups 21, 22, 23, 24 formed in an array or pattern. The array may include any number of rows of micro suction cups and any number of micro suction cups per row. Furthermore, the array may have various shapes.

According to an embodiment of the invention, the arrays of vacuum adhesion micro sized suction cups can have different spacing and sizes positioned in portions of a glove, as illustrated in FIGS. 12 and 13. Such portions may include any combination of the palm, fingers, thumb, or parts thereof. According to an embodiment of the invention, the vacuum adhesion micro sized suction cups are formed directly in or on the material of the glove, as an integral part thereof. Alternatively, arrays of micro sized suction cups are formed separately and attached to the glove by means of glue, stitching, heat sealing, RF welding, induction sealing, injection molding, transfer molding, bonding, ultrasonic, fusion, fused under pressure or any other manner. Arrays of micro sized suction cups may also be used on other objects for which enhanced gripping is useful. For example, an array of the vacuum adhesion micro sized suction cups may be positioned on soles or other parts of shoes, handles, surgical instruments, robot wheels, skis, tennis rackets, golf clubs, etc.

FIG. 2 is a cross sectional view of a suction cup along the line II-II in FIG. 1. The suction cup 23 is formed upon a base 35 of material. The same material is used for the suction cup 23 and the base 35. Preferably, the suction cup 23 is molded with the base 35. The suction cup 23 includes a stem 31 and a body 32. The body 32 has a conical inner surface 33 and a conical outer surface 34. Of course, other shapes could be used for the body, including, elliptical or other geometric shapes. According to one aspect of the present invention, the body thickness is less than 0.005 inches. According to one aspect of the present invention, the stem is cylindrical with a diameter of approximately 0.014 inches and a height of approximately 0.005 inches. Of course, other dimensions could be used. The shape of the suction cup area, number of cups, and the size of the cups can be decreased or increased to control the grip strength. The desired design would depend on the application and how much grip strength is needed to suit the application.

FIG. 3 illustrates a tool for forming suction cups in accordance with the present invention. The tool is a plate 100 having a plurality of holes 110 through the plate. The holes 110 are spaced apart to form the pattern for the suction cups. As illustrated in FIG. 3, the holes may be approximately 0.043 inches between lines. Of course, any other array density can be used. According to embodiments of the invention, array densities of 300 per square inch, 600 per square inch, 1000 per square inch, or even more are obtained. The lines of holes may be offset as in FIG. 3 or may be aligned. The number and arrangement of the holes 110 depends upon the desired positions of the vacuum adhesion micro suction cups. In addition to the plate 100, a second plate (not shown) having a plurality of pins is used in forming the vacuum adhesion micro suction cups. The plurality of pins is positioned on the second plate to align with the holes 110 in the first plate. When engaged, the pins of the second plate are disposed within the holes 110 of the first plate 100 to secure and align the plates. The first plate 100 includes a plurality of joining holes 130. FIG. 3 illustrates four joining holes 130 positioned outside the dimensions of the array of holes 110. Similar, aligned holes are present in the second plate. The joining holes 130 are threaded so that a screw or bolt can be screwed through the holes in the second plate into the first plate 100. Thus, the two plates are held tightly together during formation of the vacuum adhesion micro suction cups.

The holes 110 have a specific shape for forming the suction cups. The shape is illustrated in FIGS. 4 and 5. The holes 110 are formed of several cylindrical parts, with conical parts connecting the different diameter cylindrical parts. As illustrated in FIG. 4, a pin 120 is positioned within each hole 110. As illustrated in FIG. 5, each hole includes a first portion having a first diameter. The sides 111 of the first portion are substantially perpendicular to the surface of the plate 100. The first portion has a depth of approximately 0.005 inches or less. Of course, any other depth can be used. A second portion extends from the first portion of the hole 110. The second portion has a conical surface 112 extending from the first portion. A third portion extends from the second portion. The third portion includes a cylindrical side 113. The third portion has a depth of approximately 0.004 inches or less. Of course, any other depths can be used. Another conical surface 114 forms a fourth portion of the hole 110. The angle of the fourth portion is the same as for the third portion. A fifth portion has a cylindrical side 115 that extends to the opposing side of the plate 100. The pin 120 has a diameter substantially the same as the fifth portion of the hole. The tip of the pin has a conical surface 121 of the same angle as the second and fourth portions of the hole. When the pin 120 is engaged in the hole 110, the conical surface 121 of the tip abuts the conical surface 114 of the fourth portion of the hole 110. The tip of the pin 120 further extends into the area of the third portion of the hole. The space between the plate 100 and the pin 120 forms the shape of the suction cups.

FIG. 6 illustrates another embodiment of an array of suction cups. It is a plan view of a tool plate 150 having a plurality of holes 160 in an array for forming the vacuum adhesion micro suction cups. In this embodiment, the array shows one of many sizes that can make up a tool. Adjacent rows of holes are approximately 0.043 inches or less apart and offset from each other. Of course, any other size of array or spacing between rows can be used. Similarly, different sized holes can be used to create different sized suction cups.

The suction cups of the present invention can have different shapes. FIG. 5 is merely illustrative of a suction cup shape according to an embodiment of the invention. The structures of the tools 100 having holes 110 and pins 120 can be adjusted to provide different shaped suction cups. FIGS. 7-10 illustrate various embodiments of the invention. In FIG. 7, a tool according to a second embodiment of the present invention for forming the vacuum adhesion micro suction cups includes a plate 200 that has a plurality of holes 210. Each hole 210 includes a first portion with cylindrical sides 211 substantially perpendicular to the surface 205 of the plate 200. A second portion extending from the first portion has a conical surface 212. A third portion, with cylindrical sides 213, extends from the second portion to the opposing surface of the plate. As in the first embodiment, a pin 220 is positioned into in each 3^(rd) portion of hole 210. The pin 220 has cylindrical sides and a diameter substantially the same as the third portion of the hole 210. The tip of the pin has a conical surface 221. The angle of the conical surface 221 of the pin is approximately the same as the conical surface 212 of the second portion of the hole 210. The pin is positioned so that the tip is spaced apart from the second portion of the hole to provide a space for formation of the suction cups.

Another embodiment, as illustrated in FIG. 8, includes a tool plate 250 having a plurality of holes 260 similar to those of the first embodiment in FIG. 5. Each hole 260 includes a first portion having a first diameter. The sides 261 of the first portion are substantially perpendicular to the surface 255 of the plate 250. The first portion has a depth of approximately 0.005 inches or less. Of course, any other depth can be used. A second portion extends from the first portion of the hole 260. The second portion has a conical surface 262 extending from the first portion. A third portion extends from the second portion. The third portion includes a cylindrical surface 263 extending substantially perpendicular to the surface 255 of the tool plate 250. The third portion has a depth of approximately 0.002 inches or less. Of course, any depth can be used. A fourth portion forms a flat ring surface 264 substantially parallel to the surface 255 of the tool plate 250. A fifth portion has a cylindrical side 265 that extends to the opposing side of the plate 250. The corresponding pin 270 for this embodiment has a diameter substantially the same as the fifth portion of the hole. The tip of the pin has a flat surface 271 positioned at the center of the hole 260. A second portion of the tip of the pin 270 has a conical surface 272 of the same angle as the second portion of the hole 260. A third portion forms a flat ring 273. When the pin 270 is engaged in the hole 260, the flat ring 273 of the tip of the pin 270 abuts the flat ring 264 of the fourth portion of the hole 260. The tip of the pin 270 further extends into the area of the third portion of the hole. The space between the plate 250 and the pin 270 forms the shape of the micro suction cups.

A fourth embodiment of the suction cup shape, illustrated in FIG. 9, is also similar in shape to the first embodiment. The hole 310 has the same shape as the hole 110 illustrated in FIG. 5. The pin 320 is also similar in shape, but includes a flat tip 321 in the center of the hole 310. Similarly, a fifth embodiment of the suction cup shape, illustrated in FIG. 10 is similar in shape to that of the second embodiment of FIG. 7. The hole 360 is identical to that of the hole 210 of FIG. 7. The pin 370 includes a flat tip 371 at the center of the hole 360.

A unique process is used for manufacturing the tooling used for forming the suction cups of the present invention. A casting plate is formed from a block of steel, or similar material, plastic ceramic or similar material. A plurality of holes is drilled in the casting plate. The holes are positioned according to the desired pattern for the suction cups. Holes are drilled in the shape of the pins, as illustrated in FIGS. 4, 5, and 7-10. These holes are used to form the array of pins. FIG. 11 illustrates a structure for forming the second plate of pins. A structure is attached to the casting plate 100. The structure includes a fill plate 410 and a plurality of spacers 420. The spacers are placed between the casting plate 100 and the fill plate 410. A threaded bolt 430 extends through the fill plate 410 and spacer 420 into the casting plate 100. The fill plate 410 includes a fill hole 411 in the center.

The pins are cast into the holes in the casting plate 100 by forcing material through the fill hole 411. Any material may be used to cast the pins. Preferably, the pins are formed using a plastic or ceramic material or a similar material or metal. Once the pins are formed, they are separated from the casting plate as an array on the second plate. The spacers 420 create the holes in the second plate for attaching it to the first plate for forming the vacuum adhesion micro suction cups.

A first plate is drilled to a depth that is deeper than the holes of the casting plate. The deeper holes form the space for the conical portion of the suction cups. The space for the stems of the micro suction cups is also formed.

The second plate with the array of formed pins is reinserted into drilled holes of the first plate. The array of vacuum adhesion micro suction cups may be formed within the spaces using any known technique, such as by casting or injection molding, rotor molding or extrusion. According to an embodiment of the invention, a molding process is used to form the vacuum adhesion micro suction cups. Once the material in the molding process has cured, the plates are separated such that the pins are removed from the holes. The material can then be peeled from the first plate. The vacuum adhesion micro suction cups are withdrawn through the holes.

The technique used will depend, in part, upon the materials used for the vacuum adhesion micro suction cups. Various materials can be used depending upon the desire use of the glove or other object incorporating vacuum adhesion micro suction cups of the present invention. For medical gloves, latex, natural rubber, enzyme treated natural rubber, polyurethane, polychloroprene, neoprene, nitrile and polyisoprene or latex could be used. Of course, these are only examples of materials and the present invention is not limited to the use of any particular material.

In the process discussed above, an array of micro suction cups is formed in a molding process. The array can be then be formed into or as an integral part to a glove or other object. Alternatively, molds could be formed for the glove or other object with shaped holes for the suction cups. FIG. 12 illustrates a mold 500 used for forming gloves through a dipping process. FIG. 12 illustrates micro suction cups on the thumb 510 and finger tips 520. Of course, the vacuum adhesion micro suction cups could be placed at any location on the form and the resulting glove. A standard dipping process is used to create the gloves. When the gloves are formed and inverted, they include micro suction cups at the desired portions. Special forming tools may be used to create the form with the suction cups in a glove. This process can be used to creat medical, industrial, surgical, laboratory or exam gloves. Similar processes may be used to create other types of gloves or other objects with micro suction cups. For a glove formed by the mold 500 of FIG. 12, the suction cups are strategically placed on areas of desired enhanced gripping. FIG. 13 illustrates another embodiment with more extensively placed suction cups. The mold 600 of FIG. 13, includes suction cups on the thumb 610 and finger tips 620, as in the prior embodiment. It also includes suction cups on the entire finger 630 and on the palm 640. The locations and densities of suction cups may be varied over the area of the glove.

Having disclosed at least one embodiment of the present invention, various adaptations, modifications, additions, and improvements will be readily apparent to those of ordinary skill in the art. Such adaptations, modifications, additions and improvements are considered part of the invention that is only limited by the several claims attached hereto. 

1. A grip enhancing vacuum adhesion structure comprising of: a flexible base material; and a plurality of vacuum adhesion micro suction cups extending from the same base material, the vacuum adhesion micro suction cups having a diameter less than 0.055 inches.
 2. The grip enhancing vacuum adhesion structure according to claim 1, wherein the plurality of vacuum adhesion micro suction cups is formed jointly with the flexible base material.
 3. The grip enhancing structure according to claim 1, wherein each of the vacuum adhesion micro suction cups include: a stem extending from the base material; and a concave cup extending from the stem opposite the base.
 4. The grip enhancing structure according to claim 3, wherein the concave cup includes: a convex conical surface facing the base material having a first angle relative to the base material; a concave conical surface, having a second angle relative to the base material, wherein the first angle and second angle could be the same; and a sidewall extending cylindrically between the convex conical surface and the concave conical surface.
 5. The grip enhancing structure according to claim 4, wherein the concave conical surface extends substantially to a point, flat or radius.
 6. The grip structure material according to claim 4, wherein the concave cup includes a flat, circular surface in the center of the concave conical surface.
 7. The grip enhancing structure according to claim 4, wherein the concave cup includes a flat, ring surface between the side wall and the concave conical surface.
 8. The grip enhancing structure according to claim 1 further comprising of a material that can be absorbed into the surface of an object.
 9. The grip enhancing structure according to claim 8, wherein the surface allows absorption and transfer molding into the material substrate of a glove.
 10. A tooling system for creating at least one suction cup, the tooling system comprising of: a first plate having at least one hole extending through the plate; and a second plate, attachable to the first plate, having at least one pin extending therefrom positioned to be disposed within at least one hole when the second plate is attached to the first plate.
 11. The tooling system according to claim 10, wherein when at least one hole and at least one pin are sized such that a suction cup shaped space is formed when the second plate is attached to the first plate.
 12. The tooling system according to claim 11, wherein at least one hole includes a first portion of a first diameter and a second portion of a second diameter less than the first diameter, and wherein at least one pin has a diameter of the first diameter and is positioned within the first portion of at least one hole when the second plate is attached to the first plate.
 13. The tooling system of claim 10, wherein at least one hole includes a plurality of holes and wherein at least one pin includes a plurality of pins.
 14. The tooling system according to claim 13, wherein the plurality of holes is arranged in an array and the plurality of pins are arranged in an array.
 15. A method for forming a tooling system for forming at least one suction cup, the method comprising the steps of: forming at least one hole in a casting plate, at least one hole not extending completely through the casting plate; casting a second plate on the casting plate such that at least one pin is formed in at least one hole; a first plate is made such that when at least one hole is deeper than the pin of the second plate. A through hole is then added to the first plate such that when at least one pin of the second plate is inserted in at least one hole of the first plate, a suction cup shaped cavity remains within at least one hole.
 16. A method for forming suction cups using a tooling system having a first plate with holes therethrough and a second plate with pins thereon, the first and second plates being attachable such that the pins extend within a portion of the holes and leave suction cup shaped cavities within a portion of the holes, the method comprising the steps of: attaching the second plate to the first plate such that the pins are disposed within the holes; depositing a viscous material on a surface of the first plate opposite the second plate so that a portion of the material passes within the suction cup shaped cavities and a portion of the material remains on a surface of the first plate; curing the material to solidify the material; removing the second plate from the first plate; and removing the cured material from the first plate.
 17. A method for forming a medical glove having a plurality of vacuum adhesion micro suction cups on a portion thereof, the method comprising the steps of: creating a glove form with a plurality of suction cup shaped cavities in the glove form at the portions thereof; forming a glove using a dipping process. 